Method for producing an electrically driven vehicle

ABSTRACT

A method for producing an electrically driveable vehicle which has a sealed space for accommodating a high-voltage (HV) energy storage. A body structure delimits the space for accommodating the HV energy storage at least in an upward direction and which sealingly closes off the space at least in the upward direction and which has attachment points for the direct or indirect connection of at least one energy storage module. At least one energy storage module is connected to the body structure. A space for accommodating the HV energy storage is open at least in partial regions. An installation protection structure delimits the space for accommodating the HV energy storage in the downward direction and which sealingly closes off the space at least in the downward direction. The body structure is connected to the installation protection structure, whereby the space for accommodating the HV energy storage is sealingly closed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to German Patent application No. DE 102017 118 120.2, filed Aug. 9, 2017, which is incorporated by referenceherein in its entirety.

FIELD OF THE INVENTION

The invention relates to a method for producing an electricallydriveable vehicle which has a sealed space for accommodating ahigh-voltage energy storage. A vehicle of said type may by all meansalso be a partially electrically driveable vehicle, which may thus havean internal combustion engine.

BACKGROUND OF THE INVENTION

High-voltage (abbreviated: HV) energy storages for electric vehiclesmust be protected in the event of a crash in order to ensure that thebattery does not catch fire. It is furthermore necessary for the spacein which the HV components are situated to be sealed against the ingressof water or moisture. Therefore, in the prior art, HV energy storagesare normally composed of a battery support structure via which, in theevent of a crash, a major part of the loads are dissipated, and abattery housing cover and a battery housing base, which are connected tothe battery support structure and which thereby sealingly close the HVenergy storage. The battery support structure normally has an outerframe, inner longitudinal profiles, and transverse struts, which arearranged between the modules and which are connected to the outer frameand to the inner longitudinal profiles, and thus form thetransverse-load paths of the battery frame. The HV energy storage isconnected to the body structure in an installation step.

DE 10 2009 006 990 A1, which is incorporated by reference herein, hasdisclosed a body floor structure with a vehicle tunnel for accommodatinga battery module and with an installation plate as a support structurefor the battery module. Here, the interfaces of the battery housing thusformed are realized in air-tight form. Here, the battery modules arearranged exclusively in the region of the vehicle tunnel. The sealing ofthe space in which the battery modules are arranged is accordinglyrealized exclusively in the locally limited region of the vehicle tunnelby means of the body. The battery modules are connected to the supportstructure, which is installed onto the body from below and which close,in a downward direction, the space in which the battery modules arearranged.

DE 10 2010 011 890 A1, which is incorporated by reference herein,describes a carrier structure for the fastening of a battery module,wherein a carrier plate is connected, between two longitudinal members,to the vehicle body. A water-tight battery space is formed by a centraltunnel as a cover. The battery modules are connected to the supportstructure, which is installed onto the body from below and which closes,in a downward direction, the space in which the battery modules arearranged.

DE 10 2013 204 765 A1, which is incorporated by reference herein, hasdisclosed a storage cell structural unit with a liquid-tight and/orgas-tight housing for a vehicle. The housing has four side walls, a topwall and a base wall. The housing is connected to a right-hand and aleft-hand side sill. The right-hand and left-hand side sills are in turnconnected to one another by means of a floor panel of the vehicle body.Here, the housing is not formed as a constituent part of the body. Thesealing of the space in which the battery cells are arranged is realizedby means of the housing, not by means of the body.

U.S. Pat. No. 8,397,853 B2, which is incorporated by reference herein,has disclosed an electrical energy storage which is arranged below thebody or a central tunnel and which is delimited in a downward directionby horizontal base plates. Here, the housing is not formed as aconstituent part of the body, but rather is connected to a sill and tothe central tunnel. The sealing of the space in which the battery cellsare arranged is realized by means of the housing, not by means of thebody.

SUMMARY OF THE INVENTION

It is an object of the present invention to specify a method which, withsimple installation of the energy storage module, ensures a particularlyexpedient force flow from the energy storage module into the bodystructure, with optimum sealing of the space for accommodating the HVenergy storage.

The object is achieved by means of a method for producing theelectrically driveable vehicle which has a sealed space foraccommodating an HV energy storage has at least the following steps:

-   1. providing a body structure which delimits the space for    accommodating the HV energy storage at least in an upward direction    and which sealingly closes off said space at least in the upward    direction and which has attachment points for the direct or indirect    connection of at least one energy storage module;-   2. providing at least one energy storage module;-   3. connecting at least one energy storage module directly and/or    indirectly to the body structure, wherein the space for    accommodating the HV energy storage is open at least in partial    regions, and not closed, at least in a downward direction;-   4. providing an installation protection structure which delimits the    space for accommodating the HV energy storage at least in the    downward direction and which sealingly closes off said space at    least in the downward direction;-   5. connecting the body structure to the installation protection    structure, whereby the space for accommodating the HV energy storage    is sealingly closed.

Therefore, in the method according to aspects of the invention, thestructure that serves for supporting the battery is integrated into thebody structure. The body structure thus provides the mounting points forthe HV components. Furthermore, the body structure seals the space inwhich the HV components are situated, at least in an upward direction.The sealing in a downward direction is realized by means of aninstallation protection structure which is connected to the bodystructure after the installation of the HV components.

The advantages of this method consist in a cost reduction resulting fromfunctional integration and a considerable reduction in the number ofparts, and furthermore in the reduction of the number of interfaces, inparticular of a battery frame with respect to the body. Improvedutilization of the package is furthermore ensured. For example, a freespace for installation purposes between HV energy storage and body canbe omitted, and a battery housing cover can also be omitted. This leadsto a reduction of the dimension chain in a Z direction. More space forso-called active material, or improved seat comfort for occupants, isprovided.

It is not necessary for the method steps 1. to 5. to be performed in thestated sequence. In particular, the method steps 1. and 2. may beperformed in an arbitrary sequence before the method step 3., and themethod step 4. may be performed arbitrarily before the method step 5.

In one refinement of the method, it is provided that the space foraccommodating the HV energy storage is, in the first method step,delimited in the upward direction at least partially by a body floorstructure of the body structure and laterally at least partially by alateral body longitudinal member structure of the body structure.

In particular, the space for accommodating the HV energy storage issealingly closed toward the side by the body structure and/or theinstallation protection structure.

The sealing of the space for accommodating the HV energy storage in thebody structure is preferably performed by means of thermal joiningmethods, for example welding, and/or by application of adhesive and/orby application of plastics, such as for example PVC or a plastics foiladditionally applied after the body construction stage, which plasticsfoil is arranged above and/or below the body structure that delimits thespace for accommodating the HV energy storage, and/or by means of asingle-part or multi-part deep-drawn metal plate, which is arranged inthe region of the space, which is to be sealed, for accommodating the HVenergy storage.

A body structure is preferably provided which, on the top side of thespace for accommodating the HV energy storage, is composed of steel atleast in partial regions. The use of the material steel is particularlyadvantageous from a fire protection aspect.

With regard to method step 3., it is considered to be particularlyadvantageous if the arrangement of the at least one energy storagemodule in said step is performed, in a vehicle transverse direction, atleast substantially outside a vehicle tunnel of the vehicle in theregion of the body floor structure.

Preferably, during the connection of the at least one energy storagemodule to the body structure, in the case of an indirect connection ofthe energy storage modules to the body structure, provision is also madefor at least one structural component to be provided and connected tothe body structure, to which at least one structural component the atleast one energy storage module is directly connected. The followinginstallation sequence is thus preferably performed: connecting thestructural component to the body structure, and connecting the energystorage module to the structural component.

It is advantageous if, during the method step of the connection of theat least one energy storage module to the body structure, provision ismade for an HV assembly to be provided and connected to the bodystructure, wherein the MV assembly is composed of at least one energystorage module and at least one structural component, for example acarrier profile, and/or at least one electrical rail and/or at least onetemperature-control component/temperature-control unit, for example acooling line etc. Accordingly, an HV assembly is formed which iscomposed of at least one energy storage module and of at least onefurther component, which is subsequently connected to the bodystructure. The following installation sequence is thus performed:connecting the energy storage module to the further component to formthe HV assembly, and connecting the HV assembly to the body structure.

In particular, the HV assembly is connected in uninstallable fashion tothe body structure.

During the method step of the connection of the HV assembly to the bodystructure, it is provided in particular that the energy storage modulesand/or the structural components are connected to the body structure,wherein the energy storage modules preferably have no direct connectionto, and are not in direct contact with, the installation protectionstructure.

The energy storage modules are in particular formed with integratedtransverse-load paths. Furthermore, energy storage modules arepreferably formed with integrated temperature-control means.

The connection to the body structures and installation structure may berealized in a wide variety of ways, for example in cohesive,non-positively locking or positively locking form or by means ofcombinations of said connection types.

With regard also to the installation protection structure, it isconsidered to be particularly advantageous if the latter is connected inuninstallable fashion to the body structure.

The connection between body structure and installation protectionstructure is in particular of water-tight form. Said sealing ispreferably realized by means of adhesive bonding and/or by thecompression/pressing-on of an elastic and/or plastic seal. Said seal isfor example a window adhesive or a butyl cord.

The leak-tightness of the body structure is preferably checked, whereinthis step is performed after the step of providing the body structureand before the step of connecting an energy storage module to the bodystructure. The checking of the leak-tightness is thus performed at atime after the painting stage in the automobile manufacturing process.

It is furthermore considered to be advantageous if the leak-tightness ofthe overall system is checked. This step is performed in particularafter the step of the connection of the body structure to theinstallation protection structure.

It is preferable for all steps of the method according to aspects of theinvention or all steps of the described refinements of the methodaccording to aspects of the invention to be performed before theinstallation of the chassis/of the drive, that is to say before theso-called marriage, in the automobile manufacturing process.

The method according to aspects of the invention and the describedrefinements thereof thus make it possible for the battery supportstructure to be integrated into the body structure. The body structurethus provides the mounting points for the HV components. Furthermore,the body structure seals the space in which the HV components aresituated, at least in an upward direction. The sealing in a downwarddirection is realized by means of the installation protection structurewhich is connected to the body structure after the installation of theHV components. The battery modules are connected to the body eitherdirectly or indirectly via a further structural component (as aconstituent part of the battery pre-installation unit) which is not aconstituent part of the installation protection structure which impartsa sealing action from below. Whereas the direct and/or indirectconnection of at least one energy storage module to the body has alreadytaken place in the method step 3., the installation protection structureis installed on the body for the first time in the method step 5. Theinstallation protection structure is thus not designed as a carrierplate for the energy storage modules. The advantage is that the heavybattery modules are connected to the body and do not stand on the lowerplate. A further advantage is that said lower cover has a spacing to thebattery modules, which serves as a deformation zone in the event of anobject being run over and in bollard tests. The sealing of the space inwhich the battery modules are arranged is realized by means of the bodystructure and the installation protection structure.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features of the invention will emerge from the subclaims, fromthe appended drawing and from the description of the exemplaryembodiments depicted in the drawing for the purposes of illustrating avehicle produced in accordance with the method, without being restrictedthereto.

In the drawing:

FIG. 1 shows an exemplary illustration of the space for accommodating anHV energy storage in an electrically driveable vehicle, specifically inan exclusively electrically driveable passenger motor vehicle,

FIG. 2 shows an exemplary illustration of the overall structure such asis realized after the method step 5., Illustrated for a left-hand halfof the vehicle,

FIG. 3 shows an exemplary illustration of the arrangement of the batterymodules substantially in the region of the body floor structure, outsidethe region of the vehicle tunnel, after the method step 3., in a sectionin a Y-Z plane (X: vehicle longitudinal direction, Y: vehicle transversedirection, Z: vehicle vertical direction),

FIG. 4 shows the arrangement as per FIG. 3 in a view Z as per FIG. 3,viewed from below.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows, in the section in the Y-Z plane, a space 1 foraccommodating an HV energy storage. Said space 1 is delimited on bothsides of the vehicle in each case by a lateral body structure 2. At thetop, the space 1 is delimited by a body floor structure 3, and at thebottom, said space is delimited by an installation protection structure4. The stated parts of the body structure constitute the bodyshellstructure of the vehicle.

FIG. 2 shows the relevant region of the vehicle after the stepsaccording to aspects of the invention for the production thereof, thatis to say after the method step 5. Only the left-hand half of thestructure sectioned in the Y-Z plane is shown. The right-hand half is ofmirror-symmetrical form about a plane of symmetry 5, which constitutesthe plane of symmetry of a central longitudinal profile 6 and which isarranged in an X-Z direction. The illustration shows a lateral bodystructure 2 and a body tunnel structure 7 above the central longitudinalprofile 6. An installation bridge 8 is mounted in the centrelongitudinal profile 6, and an installation element 9 is mounted in thelateral body structure 2. By means of the installation bridge 8, anenergy storage module 10—a battery module—is mounted in the body tunnelstructure 7, and the energy storage module 10 is mounted in the lateralbody structure 2 by means of the installation element 9.

FIG. 3 shows, for the state after method step 3., that is to say beforethe connection of the installation protection structure 4 to the bodystructure, the regions 11 in which the energy storage module 10 isarranged in the region of the body floor structure 3 and a region 12 inwhich the energy storage module 10 is arranged in the region of the bodytunnel structure 7. FIG. 4 shows, for said state, said regions 11 and 12in a view from below. Also schematically indicated is a rear axle 13 ofthe vehicle and that end 14 of the vehicle which faces toward the rearbumper of the vehicle.

With regard to the individual method steps for the production of theelectrically driveable vehicle, including the refinement of said method,reference is made to the detailed description preceding the descriptionof the figures.

LIST OF REFERENCE DESIGNATIONS

-   1 Space-   2 Lateral body structure-   3 Body floor structure-   4 Installation protection structure-   5 Plane of symmetry-   6 Central longitudinal profile-   7 Body tunnel structure-   8 Installation bridge-   9 Installation element-   10 Energy storage module-   11 Region-   12 Region-   13 Rear axle-   14 End

What is claimed is:
 1. A method for producing an electrically driveablevehicle which has a space for accommodating at least one energy storagemodule, the method comprising the steps of:
 1. providing a bodystructure which delimits the space for accommodating the at least oneenergy storage module at least in an upward direction and whichsubstantially sealingly closes off said space at least in the upwarddirection and which has attachment points for indirect connection of theat least one energy storage module;
 2. providing the at least one energystorage module;
 3. connecting the at least one energy storage moduleindirectly to the body structure, wherein the space for accommodatingthe at least one energy storage module is open at least in partialregions, and not closed, at least in a downward direction, wherein,during indirect connection of the at least one energy storage module tothe body structure, provision is also made for at least one structuralcomponent to be provided and connected to the body structure, to whichsaid at least one structural component the at least one energy storagemodule is directly connected;
 4. providing an installation protectionstructure which delimits the space for accommodating the at least oneenergy storage module at least in the downward direction and whichsealingly closes off the space at least in the downward direction; 5.connecting the body structure to the installation protection structure,whereby the space for accommodating the at least one energy storagemodule is sealingly closed.
 2. The method as claimed in claim 1, whereinthe method steps
 1. and
 2. are performed in an arbitrary sequence beforethe method step 3., and the method step
 4. is performed arbitrarilybefore the method step
 5. 3. The method as claimed in claim 1, whereinthe space for accommodating the at least one energy storage module is,in the method step 1., delimited in the upward direction at leastpartially by a body floor structure of the body structure and laterallyat least partially by a lateral body longitudinal member structure ofthe body structure.
 4. The method as claimed in claim 1, wherein thespace for accommodating the at least one energy storage module issealingly closed toward at least one side by the body structure or theinstallation protection structure.
 5. The method as claimed in claim 1,wherein the sealing of the space for accommodating the at least oneenergy storage module in the body structure is performed by at least oneof thermal joining methods, application of adhesive, application ofplastics, a single-part deep-drawn metal plated, or a multi-partdeep-drawn metal plate, which is arranged in the region of the space foraccommodating the at least one energy storage module.
 6. The method asclaimed in claim 1, wherein the body structure, on the top side of thespace for accommodating the at least one energy storage module, iscomposed of steel at least in partial regions.
 7. The method as claimedin claim 1, wherein the arrangement of the at least one energy storagemodule in the third step is performed, in a vehicle transversedirection, at least substantially outside a vehicle tunnel of thevehicle in the region of a body floor structure.
 8. The method asclaimed in claim 1, wherein, during the connection of the at least oneenergy storage module to the body structure, provision is made for ahigh-voltage (HV) assembly to be provided and connected to the bodystructure, wherein the HV assembly is composed of at least one of (i.)the at least one energy storage module and the at least one structuralcomponent, (ii.) at least one electrical rail, or (iii.) at least onetemperature-control component/temperature-control unit.
 9. The method asclaimed in claim 8, wherein, during the connection of the HV assembly tothe body structure, the at least one energy storage module or the atleast one structural component are connected to the body structure,wherein the at least one energy storage module has no direct connectionto, and is not in direct contact with, the installation protectionstructure.
 10. The method as claimed in claim 1, wherein the at leastone energy storage module is formed with integrated transverse-loadpaths.
 11. The method as claimed in claim 1, wherein the at least oneenergy storage module is formed with integrated temperature-control. 12.The method as claimed in claim 1, wherein the connection between thebody structure and the installation protection structure is of cohesive,non-positively locking and/or positively locking form.
 13. The method asclaimed in claim 1, wherein the connection of the body structure and ofthe installation protection structure is of water-tight form, and thesealing is realized by at least one of adhesive bonding, orcompression/pressing-on of an elastic, plastic seal.
 14. The method asclaimed in claim 1, further comprising the step of: checking theleak-tightness of the body structure, wherein the body structureleak-tightness check is performed after the step
 1. of providing thebody structure and before the step
 3. of connecting the at least oneenergy storage module to the body structure.
 15. The method as claimedin claim 1, further comprising the step of: checking the leak-tightnessof the overall system, wherein the overall system leak tightness checkis performed after the step
 5. of connecting the body structure to theinstallation protection structure.
 16. The method as claimed in claim 1,wherein all steps 1.-5. are performed before the installation of achassis of the vehicle.